This project covers the design of cranial flap implants for neurosurgery and maxillofacial procedures - all derived directly from each patient's CT scan data.
The Process
The workflow begins with a CT scan, which is converted into a 3D medical image. From there, the implant is modelled to match the patient's exact anatomy. Each design and simulation is validated on a virtual platform and cross-checked against printed anatomical models before any implant is manufactured.
Outcomes
Five patients from neurosurgery and five from maxillofacial were successfully implanted. The new patient-specific procedure delivered:
- Improved implant quality and fit
- Shorter operation times
- Better aesthetic outcomes for every patient
Why Patient-Specific Implants?
Standard off-the-shelf implants require intraoperative adjustment, which extends surgery time and increases infection risk. By manufacturing to the exact patient geometry, 3D Gens eliminates that adjustment step entirely - the implant goes in and stays in.
This work is part of 3D Gens' broader Medical / PSI programme, which covers titanium mesh, solid and PEEK implants, self-drilling screws, and interlink plates across craniofacial and spinal applications.